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Sag resistant, formaldehyde-free coated fibrous substrate

a technology of formaldehyde-free and fibrous substrates, applied in the direction of synthetic resin layered products, transportation and packaging, coatings, etc., can solve the problems of low ph, low ph, and loss of modulus of substrates, and achieve the effect of hindering crosslinking reaction and not losing its modulus

Active Publication Date: 2018-07-10
AWI LICENSING
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The coating effectively resists sag in fibrous substrates by maintaining a high modulus and being environmentally friendly, compatible with other materials, and avoiding equipment corrosion, thus improving mechanical strength and compliance with emission standards.

Problems solved by technology

More specifically, after absorbing moisture, the substrate loses its modulus and sags by its gravity.
However, the main drawback of these formaldehyde-free binder solutions is their low pH which is often not compatible with other coatings and / or causes corrosion of processing equipment.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0015]The waterborne coating BC #1 was made in the following procedure: 247.0 g ammonium polyacrylic acid (38% w / w) was added into a mixer containing 521.8 g water. While mixing, 102.5 g Dextrose, 1.0 g Tergitol TMN-6 (wetting agent), 2.6 g defoamer, 1.2 g biocide, and 1519.7 g filler slurry were added in sequence to the mixer. The finished coating had solids content of 55%, Brookfield viscosity of 3,400 cps, pH of 8.9, and filler to binder (F:B) ratio of 6:1.

[0016]The coating was applied by spray to the back side of three types of ceiling panels. They all contain different levels of reinforcing fibers (either mineral wool or glass fiber). Panel #3 was a kilned product containing additional clays. The dry application weight was 10 grams per square foot. In order to balance the ceiling tile stress caused by drying the back coating a prime coating (PC #1) comprising a filler to binder ratio of 5:1 and 50% solids was also applied to the face of ceiling panel with dry application weight...

example 2

[0020]The waterborne coating BC #2 was made in the following procedure: 576.0 g ammonium polyacrylic acid (38% w / w) was added into a mixer containing 387.8 g water. While mixing, 239.3 g Dextrose, 1.0 g Tergitol TMN-6, 2.6 g defoamer, 1.2 g biocide, and 1187.5 g filler slurry were added in sequence to the mixer. The finished coating had solids content of 55%, Brookfield viscosity of 1,100 cps, pH of 8.9, and filler to binder (F:B) ratio of 2:1. Following the same coating application, coating curing, and panel sag testing procedure as described in Example 1 three different ceiling panels were evaluated using this back coating. The converted sag data are shown in Table I.

[0021]Formaldehyde emission testing using the California CA 1350 method has shown that Panel #3 with BC #2 coating and bare Panel #3 both had non-detectable emissions levels. Therefore, the BC #2 coating did not add detectable formaldehyde emissions in this test. These panels would easily met the formaldehyde emission...

example 3

[0027]The waterborne coating BC #5 was made in the following procedure: 328.0 g SMA-1000H from Sartomer Co. was added into a mixer containing 291.0 g water. While mixing, 38.0 g glycerol, 1.0 g defoamer, 1.0 g biocide, and 340.0 g Kaolin clay were added into the mixer. The resulting coating had 50% solids, 630 cps Brookfield viscosity, and filler to binder ratio of 2:1. Following the same coating application, coating curing, and panel sag testing procedure as described in Example 1 Panel #1 (with about 10% reinforcing fiber) was tested using this coating. The coated panel had a sag value of −198 mils after 4 humidity cycles as shown in Table II.

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Abstract

The present invention relates to an improved formaldehyde-free coated fibrous substrate. The coating includes a crosslinked binder system which forms three dimensional networks when heat cured. After the coating is applied to the back of fibrous substrate and cured, the coating is capable of hygroscopic expansion which imparts excellent anti-sag properties. The coating is compatible with other coating systems with neutral or mild alkaline pH. The improvement being the binding system is neutralized with a volatile base so that it evaporates quickly so as not to hinder the cross-linking reaction.

Description

BACKGROUND OF THE INVENTION[0001]The present invention is related to coated panels, and, in particular, to a formaldehyde-free coating that is applied to a major exterior surface of a fibrous panel to resist sag.[0002]Fibrous substrates are light weight, porous composite materials which are used for many different purposes including panels in suspended ceiling systems. They are produced from a water based slurry mixture containing fibers, a binding system and other additives. Fibers, which are typically used as reinforcing materials, include mineral wool, glass and cellulosic fibers. Binding systems, which hold the fibers and other additives together, include starches, latex, reconstituted paper products and other polymeric materials. Other additives include fillers such as expanded perlite, clay, etc.[0003]It is widely known in the art that varying the material percentages of the aforementioned components ultimately impacts the physical and mechanical properties of the fibrous subs...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): B32B27/20C09D7/63B32B27/04C09D5/02C09D133/02E04C2/16E04C2/24C09D125/08C08K5/053
CPCC09D5/024C09D7/63C09D133/02E04C2/16E04C2/246C08K5/053Y10T428/31971Y10T428/251Y10T428/31507Y10T428/31739Y10T428/31786Y10T428/31931Y10T428/31935C09D125/08
Inventor LU, LIDACALDWELL, KENNETH G.
Owner AWI LICENSING